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Whitepaper Fuel Systems PDF
Whitepaper Fuel Systems PDF
FUEL SYSTEM
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FUEL SYSTEMS
The fuel systeem is the most sophisticated, expensive and critical of all engines systems. Engine
performance, economy and durability depend on proper performance of the fuel system. Keeping fuel
clean and using high quality, high efficiency fuel filters will allow the fuel system components to
perform properly until the engine reaches overhaul life.
Fuel system problems are largely confined to accelerated abrasive ear or seizure of unit injectors.
Injector seizure may also result in contingent damage to valve train components. The single large
problem is:
short unit injector life due to excessice abrasive particles in the fuel
Microscopic abrasive particles damage surfaces in the injector, causing
internal leakage of hight pressure fuel and low engine power/
abrasive particles are inherent in most fuels. Some fuels have very large amounts of
abrasives.
In this whitepaper we would like to give you more information about how fuel systems work, what
contamination does to a fuel system and what you can do to prevent this.
The engine driven transfer pump delivers fuel to the unit injectors via the secondary fuel filter. The
pump is equipped with a pump-mounted safety valve and the fuel flow at rated rpm is listed in the
technical data and varies with engine speed. The unit injector, either mechanically or hydraulically
actuated, combines the functions of pumping, metering and injecting into a single unit. It is located
near the center of the combustion chamber in each cylinder head, between the rocker arms. External
manifolds supply fuel from the transfer pump to the injectors, eliminating the need
for high pressure fuel lines. Fuel continuously circulates through the injectors, and the excess fuel that
is not used for combustion cools the injectors and is returned to the fuel tank via the pressure
regulating valve. This excess fuel also aids in the purging of air from the system. The fuel delivery
pressure to the injectors is controlled by a pressure regulating valve. The pressure regulator must be
adjusted at the installation site in order to provide the proper fuel pressure to the injectors.
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The manual fuel priming pump is recommended if no electrical priming pump is available. The manual
pump helps to bleed air from the fuel piping before initial engine operation and following engine
maintenance such as filter element changes and injector replacement. Caterpillar also recommends
the use of a duplex primary fuel filter prior to the engine driven fuel transfer pump. When used, the
duplex primary fuel filter is installed, remotely from the engine, in the fuel transfer pump suction piping.
Their are different types of fuel systems: MEUI, HEUI and Common Rail fuel systems.
FUEL INJECTION
The performance of diesel engines is heavily influenced by their injection system design. In fact, the
most notable advances achieved in diesel engines resulted directly from superior fuel injection system
designs. While the main purpose of the system is to deliver fuel to the cylinders of a diesel engine, it is
how that fuel is delivered that makes the difference in engine performance, emissions, and noise
characteristics. Unlike its spark-ignited engine counterpart, the diesel injection system delivers fuel
under extremely high injection pressures. This aspect implies that the system component designs and
materials should be selected to withstand higher stresses, while still performing for extended durations
matching the engine’s durability targets. Greater manufacturing precision and tight tolerances are also
required for the system efficient function. In addition to expensive materials and manufacturing costs,
diesel injection systems are characterized by more intricate control requirements. All these features
add up to a system whose cost may represent as much as 30% of the total cost of the engine.
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COMBUSTION
In diesel engines, fuel is injected into the engine cylinder near the end of the compression stroke.
During a phase known as ignition delay, the fuel spray atomizes into small droplets, vaporizes, and
mixes with air. As the piston continues to move closer to top dead center, the mixture temperature
reaches the fuel’s ignition point, causing instantaneous ignition of some pre-mixed quantity of fuel and
air. The balance of fuel that had not participated in premixed combustion is consumed in the rate-
controlled combustion phase, also known as diffusion combustion
The interface between the fuel injection system and the combustion process is in the form of a fuel
spray. In fact, it could be said that the complication and sophistication of the control of the fuel injection
system is mainly for the purpose of delivering a proper spray into the cylinder. The component
responsible for delivering the fuel spray is the injector nozzle. The spray is formed with the help of a
differential pressure across its spray holes. The fuel is broken into droplets of different sizes and
concentrations in the spray. The combustion process depends a great deal on the development of the
spray from the start of injection, even before the spray is fully developed. The behavior of that spray is
very important to the combustible mixture formation and start of ignition. In addition, the behavior of
the spray after the end of injection and fuel cut-off is very critical for the emissions formation.
Meeting the demand for lower emissions, better fuel economy and higher performance.
HEUI injector technology is changing the way equipment owners, technicians and operators think
about diesel engine performance. HEUI performance surpasses mechanical unit injectors and
conventional electronic unit injectors, bringing new value to your investment in engines and machines.
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A close look at the HEUI System
1. HEUI Injector Uses hydraulic energy (as opposed to mechanical energy from the engine camshaft)
from pressurized engine lube oil for injection. The pressure of the incoming oil (800 to 3300 psi)
controls the rate of injection, while the amount of fuel injected is determined by the ECM.
2. Electronic Control Module (ECM)
This sophisticated on-board computer precisely manages fuel injection and other engine systems. The
HEUI injector solenoid is energized by an electronic signal generated in the ECM. Using input from
multiple
sensors, the ECM’s dual microprocessors use proprietary software and customersupplied
performance parameters to produce maximum engine performance under any conditions.
3. High Pressure Oil Pump (Hydraulic Pump)
The variable displacement axial pump features a built-in reservoir to immediately supply oil at cold
starts.
4. Injector Actuation Pressure Control Valve (JAPCV)
This electronically operated valve controls oil pump output and injection pressure
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HEUI brings new value to your engine and equipment
investment.
Engines equipped with HEUI injectors have outstanding
response and improved high altitude operation. The ability to
inject fuel at any crank angle results in up to 2.7 percent better
fuel economy compared to scroll mechanical injectors. Optimum
fuel economy also means reduced gaseous emissions and less
white smoke during cold engine starts.
The control of fuel delivered during ignition delay and main
injection, known as rate shaping, is made possible by the HEUI’s
ability to operate independent of engine speed. Rate shaping
modifies engine heat release characteristics, which also helps
reduce emission and noise levels. Rate shaping
optimizes engine performance by varying the idle and light load
rate characteristics independent of rated and high load
conditions.
CONTAMINATION
Contamination control is increasingly important for maximizing importance and service life in fuel
systems. Some Cat fuel systems exceed pressures of 30.000 psi in order to deliver more horsepower,
better fuel economy and fewer emissions. This necessitates tolerances smaller than five microns
between parts. These tolerances and injection pressures make fuel systmes more vulnerable to wear
and abrasion.
Injector Plungers and Barrels – Abrasive particles cause wear between an injector’s plunger
and barrel. Contaminants scuff metal surfaces, causing metal-to-metal contact and eventuel
injector seizure.
Control valves – Contaminants damage valves that control fuel pressures, eroding mating
parts of the valves. This excessive wear causes leaks and eventuel loss of engine power.
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Size of contamination
A particle five microns across can damage fuel systems. A micron is onmillionth of a meter. To give
you an idea of how small that is, an average human hair is 80 microns in diameter. Tolerances in
Caterpillar fuel injectors are 1/20th the diameter of a human hair. It’s easy to understand how even
small contaminations can damage today’s fuel systems.
Sources of contamination
In the fuel – contaminants can enter during storage or transportation of fuel. A reliable
supplier, filtered dispensing and periodic sampling and testing assures consistent quality.
During operaton – Airborne particles can be drawn into your fuel tank through the vent tube. A
fuel tank vent can ingest dust when it is not properly sealed.
External – Contamination can enter during maintenance and service, even when chaning
filters.
Measuring Contamination
Contamination is measured by counting particles and reported by comparing those results to an
International Standards Organization (ISO) code. This ISO standards refers to the number of particles
in three different size categories contained in a one-milliliter sample. The first number refers to the
number of particles that are greater than 4 microns, the second number refers to particles that are
greater than 6 microns, and the third number refers to particles that are greater than 14 microns.
An ISO leverl of 18/15/13 would mean that a one-milliliter sample of fuel contains ISO Code 18 or
between 1300-2500 particles greater than 4 microns, ISO code 15 or between 160-320 particles
greater than 6 microns, and ISO code 13 or between 40-80 particles greater than 14 microns. If the
contamination level is allowed to rise one ISO code, the amount of particles for that size will double.
Filtering contamination
The precision components in today’s fuel systems require specially designed fuel filters. The critical
component is a super-fine filtration media that removes more than 98 percent of particles 2 microns
and larger. Quality filters feature:
Maximum engine performance and fuel economy
Reduced exposure to abrasives
Reduced wear on injectors and pumps
Fewer fuel system adjustments
Easier starting
Longer filter life
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Keep all fuel equipment clean.
Maintain all hoses, gaskets and seals in your fuel storage and transfer equipment.
Use line filters on all fuel transfer equipment.
Never transfer fuel into open containers.
Only purchase fuel from a reliable source, and demand periodic testing to ensure quality.
Repair any fuel line leaks immediately.
Keep fuel tank breathers open and functioning properly. Use an appropriate breather.
Never operate a machine without the fuel cap.
If a fuel cap does not seal properly, replace it immediately.
In case you have any questions concering fuel systems, contamination or fuel filters, please do not
hesitate to contact Pon Power, phone: +31 (0)78-6 420 420.
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